Panel wall construction



` Jan. 17, 1939,

J. E. @RINCKERHOFF Er AL PANL WALL CONSTRUCTION Filed May 14, 19:55

9 Sheets-Sheet l HHMMWFMMMMMMMWMWWVMMWVMMWWWMWW.

INVENTORS cker/70H? JamesEEm/z Anthony M Koh/@r Car] 5f Reed f la-)lancent Waver Smit/1.

ATTONEY.

/n Imm Jan. 17, 1939- J: E. BlNcKERHOFF VEl' AL '2,144,598

PANEL WALL CONSTRUCTION Filed May 14, 1935 n 9 sheets-sheet 2 INV ENTORS mes E Brmcker17:"1,` A mhonyl Koh er;

Carl 5. Feed ATTORNEY.

Jan. 17, 939. .1. E. BRINCKERHOF'F Er Al..v 2,144,598

PANEL WALL CONSTRUCTION Filed May 14, 1935 9 Sheets-Sheet 3 242 0 27a 2O a C 22464 F1' 5f 5 C) 22@ 1 ENToRs 222 256 Jan/@5E BMC/mdf C) -JlnfnJl/QMQ'o/el F 220 BY Vlhcenz l/l/eaver Smi ATTORNEY.

Jan. 17, 1939. J. E. BRlNcKERHoFF n AL 244598 PANEL WALL CONSTRUCTION Filed May 14, 1935 9 Sheets-Sheet 4 80 C 35' n 76 O f -66 ;4 y Q ggf.; )35 3/ 0 Q 22 O FJ- 7 0 a rf on 0 ez; @g f "96; BY zf/ff Wff 5mm/7. Q m o J l ATTORNEY.

5m. 17, 1939. J. E. BRINCKERHOFF Er AL PANEL WALL CONSTRUCT ION Fild May 14, 1935 I 9 Sheets-Sheet 5 Mem/er Jan. v17, 1939. .1. E. BRlNcKl-:RHOFF ET Al. 2,144,598

PANEL WALL CONSTRUCTION Filed May 14, 1935 9 Sheets-Sheet 6 TTORNEY Jan. 17, 1939. J. E. BRINCKERHOFF ET AL 2,144,598

PANEL WALL CONSTRUCTION Filed May 14, 1935 9 Sheets-Sheet 7 Qian. 17, 1939- J. E. BRINCKERHQFF Er AL.

PANEL WALL CONSTRUCTION Filed May 14, 1935 Fig? 24 9 Sheets-Sheet 8 Jan. 17, 1939.

J. E. BRINCKERHOFF Er AL I2,144,598

PANEL WALL CONSTRUCTION Filed May 14, 1935 9 Sheets-Sheet 9 Fig? 26 86- Zic? 2 229 ATTRNEY.

D nace conditions at Patented Jan. 17, 1939 UNITED STATES PANEL WALL CONSTRUCTION James E. Brinckerhoff, Orange, N. J., and Anthony'M. Kohler and Carl and Vincent Weaver Smit said Brinckerhoff and said The Babcock & Wilcox Newark, N. J., a corpor Smith assiznors to The New York, N.

N. Y., N. Y.; signors to said Reed and said Lummus Company, ration of Delaware S. Reed, Nieuw York, ushill. Kohler as- Company,

ation of New Jersey, and

Y., a corpo- Application May 14, 1935, Serial N0. 21,406 l-Claims. (Cl. 110-1) A This invention relates to furnaces and other refractory faced constructions exposed to high temperatures. It is exemplified herein as a thin, lightweight, air tight encasement for steam boilers.

It is an object of the invention to provide a sectional refractory faced encasement including independently replaceable panel sections having an exceptionally low coeflicient of thermal conductivity relative to its weight. The insulating iirebrick used in these sections are lightweight refractories having the ability to withstand furhigh temperatures with low heat conductivity.

It is a further object of the invention to promote power supply economies by providing a furnace encasement construction which is especially advantageous for the upper sections of generating station boilers which are of great height.

Not only does the invention promote the dependability of power -generation by reducing boiler outage, but installation and repair costs are also substantially reduced thereby. 'I'he time' necessary to make repairs is also materially reduced.

' In the construction of modern central station power units, of which the Potomac Electric Power Companys latest unit is an example, efficiency and economy considerations have led to furnace and boiler structures of great wall expanse and fof considerable height. In many cases heavy pressure parts of the boilers are located at distances from 75 to 100' above the In order to attain high eiciencies, high steam pressures and high combustion rates are involved. To effect the high combustion rates means are employed for inducing high drafts. In order that such means may be eiiective the present invention provides a boiler and furnace encasement which is airtight. 'I'he induced draft will not be lost by leakage. Because of the lightweight of the illustrative encasement units they may be handled with facility at the high elevations of the upper parts of power plants. This characteristic also eliminates a considerable portion of original installation cost which would be involved in connection with boiler encasements employing standard rebrick and the many heavy castings and consequent heavier supporting steel of prior art structures.

Among other objects of the invention are: the provision of `a boiler and furnace encasement having independentlyreplaceable and removable panel units interiitting with the steel framework and adjacent units in airtightrelationship and including a refractory brick lining, insulation, and eet metal outer closure combined in a rigid unit; the

casing section, and: the provision of furnace encasement panel elements adapted by a change in their spacing to form parts of a 9 or a 41/2" refractory wall when iirebrick of standard dimensions are employed.

Other objects of the invention will appear as the accompanying description proceeds.

The invention will be described with reference to the accompanying drawings in which illustra.- tive embodiments of the invention are indicated.

In the drawings:

Fig. 1 is a perspective view showing a section of the boiler wall.

Fig. 2 illustrates the upper part of the encase ment wall in side elevation, the lower part of the structure showing the furnace in vertical cross section.

\ Fig. 3 is a broken away perspective view of one embodiment of the invention.

Fig. 4 is a vertical sectional view of the embodiment illustrated in Fig. 3.

Fig. 5 is a partial horizontal section showing the Fig. 3 embodiment andincluding a 4%" refractory wall.

Fig. 6 is a. horizontal bodiment showing the ranged to form a 9" refractory Wall.

Fig. 7 is a broken away perspective view of another embodiment of the invention.

Fig. 8 is a vertical section of the Fig. 7 embodiment.

Fig. 9 is a horizontal section of the Fig. 7 embodiment when its parts are arranged to form a 4%" refractory wall.

Fig. 10 is a horizontal section of a. 9" refractory wall constructed in accordance with the Fig. 7 embodiment.

Fig. 11 is a partial side elevation of the embodiment indicated in Figs. 7 and 8.

Fig. 12 is a partial side elevation of the embodiment illustrated in Figs. 3 and 4.

Fig. 13 is a vertical section through a furnace wall and a. furnace arch embodying additional features of the invention.

Fig. 14 is a partial enlarged sectional section of a part of the wall structure indicated in Fig. 13.

Fig. 15 is a small horizontal section taken section of the Fig. 3 emupon the line I5-I5 of Fig. 14

insulating flrebrick ar- A Fig. 16 is a vertical section of another embodiment of the invention.

Fig. 17 is a partial horizontal section on the line ll--ll of Fig. 16.

Fig. 18 is a vertical section showing a bottom supported wall panel structure.

Fig. 19 is a vertical section taken at the upper corner of a furnace structure and showing a suspended arch in which means are provided forpermitting the anchor rods to be tightly secured against the sheet metal panels without fracturing the bricks.

Fig. 20 is an enlarged .detail of the suspended arch shown in Fig. 19.

Fig. 2 1 is a vertical section taken upon the line 2|-2l of Fig. 20.

Fig. 22 is a vertical section of a panel wall furnace construction having means for sealing the expansion joints between the panels.

Fig. 23 is a vertical section showing the expansion joint construction of the Fig.V 22 embodi.

ment on an enlarged scale. l

Fig. 24 is a partial horizontal section .taken on the line 24-24 of Fig. 23 and showing the relation of the buckstay steel to adjacent panels.

Fig. 25 is a horizontal section through a corner of a boiler and furnace encasement showing the relative arrangement of the panels and the buckstay steel.

Fig. 26 is a partial perspective view showing the arrangement of elements in the column construction of the Fig. 1 furnace.

Fig. 2'7 is a vertical sectional view illustrating the manner in which the refractory subunits are independently removed from the sectional panel wall construction. l

Fig. 28 is a partial horizontal section of the Fig 3 wall taken at a level just above the tops of the upper ends of the upright anchor rods.

Fig. 29 is a detail of the Fig. 26 column construction, illustrating in a horizontal section the relationship of the panels to the column construction.

Fig. 30 is a partial section of another embodiment. This ligure represents furnace constructions in which a panel encasement wall may be employed in connection with rods which are passed through openings in the tile |90. Breakage of the tile by excessive force exerted by the tension member 36 is prevented by reason of the stop |84. i

Fig. 31 is a perspective view of the tier bracket. Figure 32 is an enlarged transverse vertical section through a part of the Wall structure indicated in Figure 27 of the drawings. This iigure shows a section through bracket 229 and indicates the extension of the brick aligning member 234 through an opening in the bracket.

The elciency of furnaces including the illustrative insulatingrebrick refractories in the panel furnace constructions shown in the drawings is increased (with reference tol furnaces using solid iirebrick) by the reduction of radia-- tion losses. This is due to their very low heat transmission. When they are used in certain types of furnaces which are in intermittent operation, as is the case in heat-treating furnaces, the efficiency isalso increased by reason of the fact that only a small amount of heat is necessary to bring the walls up to operating temperature. The latter figure is about 6% ofthe B. t. u.s required to similarly heat to the same temperature a furnace of equal wall area and equal radiant heat loss built of solid flrebrick. A panel wall construction similar to that shown in Fig. 9 or in Fig. 5 of the drawings with a 41/2 brick thickness will have a heat flow of 350 B. t. u. per square foot per hour with a hot face temperature of 1800 deg. Fahr., or less than half of an 18 solid ilrebrick wall in which the heat flow is about 720 B. t. u. per square foot per hour.

Considering wall constructions such as those indicated in Figs. 6 and 10 as having insulating rebrick weighing about 40 lbs. per cubic foot, the outside casing temperature of the panel with 9" brick thickness and with a hot face temperature of 2000 deg. Fahr. will be approximately the same as that of a 131/2 solid rebrick wall with 2 of insulation.

The separate ceramic refractories which constitute the inner parts of the furnace constructions described herein are of lightweight. They are porous to a certain extent and their thermal conductivity is of such an order that there may be a temperature in excess of 2000 deg. Fahr. at their furnace ends while the temperature at their opposite ends when the bricks are considered'the long way is not above 100 deg. Fahr., the heat conductivity of the bricks being only 25 to 40%, of standard heavy refractories where their weight is only 1/3 that of the heavy'refractories. Their weight may vary from 1/2 to 1/6 the weight of standard heavy ceramic firebricks. 4

In connection with the above advantages it is vinteresting to note a comparison in the weights of the panel wall constructions shown in the drawings when compared to walls using solid, or

standard iirebrick. The weight of a panel consisting of 9" of the illustrative brick, 1/4" millboard casing, and buckstays, (referring to such a structure as that shown in Fig. 10) is approximately 45 lbs. per square foot. Referring to such a construction as that shown in Fig. 9, the weight of the panel with i1/2" of the illustrative brick, 11/2" of block insulation, casing and buckstays is approximately 35 lbs. per square foot. These weights are in marked contrast with an 18" firebrick Wall, or with a conventional type sectional flrebrick wall of standard firebrick with 9" of rebrick, 4" of insulation, casing and castings. Such a wall weighs about 130 lbs. per square foot. This comparison shows a saving of 95 lbs. per square foot of wall area. 'I'his amounts to a saving in Weight of over 40 tons in one side 30' section of a boiler encasement. Assuming that the section 44 of the installation indicated in Fig. 2 is of such dimensions there will be a saving in weight of approximately tons deadweight. From this it will be appreciated that the cost of the entire installation will be materially de.. creased.

These large savings in weight and the consequent greater savings in installation costs resulting from use of the illustrative constructions are possible only with the use of refractories having low heat conductivity and lightweight, together with such other properties that they may be readily machined, drilled or sawed. This is impossible with the standard refractory firebrick, and by reason of these properties very lightweight steelwork may be used in the wall construction. I'his steelwork receives adequate protection with a relatively small thickness of refractory in front of it, by reason of the low heat conductivity of the illustrative insulating firebrick. The protection against damage afforded thereby prevents the steelwork and the supporting structure from attaining weakening temperatures. By reason of the insulation 34 no wide joints v iications of this steel panel, foot the above described properties o1' the illustrative insulating flrebrick, it is possible to build a dry assembled wall because the brickscan be made so uniform by sawing and grinding that they present a substantially complete furnace face with between the courses of brick or Such perfect fltting of with standard ilrebrick. the illustrative refractories and the materials from. which they are made are such that they constitute a building structure in which there are small uniformly distributed voids of the same order of magnitude. The extent of the voids is indicated by the fact that they may constitute up to oi' the volume of the individual refractories. Also, the rigidity of` the refractories, and their resistance to crushing stresses are suiiicient to permit'them -to be arranged in bottom supported columns, the height of which corresponds generally to the heights of the illustrative panels.

In general, the drawings show two types of the panel construction for furnacea. The flrst type iswhat the bricks themselves. the bricks is impossible 'Ihe manufacture of this type the entire panel structure, or wall section, may be manufactured as a unit in the factory or at some loc lttion apart from the actual site of the furnace. Such' units may be shipped as separate articles ,o the site at which the furnace is to be erected and separately handled and placed in position. is shown in Fig. 1 of the drawings.

11, I4, 15, 16, 17 and 19 also show different moditype. i

The second, or sectional panel construction is indicated in Figs. 3 and 4 of the drawings. In this type the refractorics are carried by supporting steelwork which is independent of the panels or casing plates. Upon removal of the casing and the insulation, the separate refractory tiers in the panel area may be removed separately.

In both types of illustrative structions the sections consist of porous insulating rebrick backed by insulating material and a steel casing member. In either case, the wall sections are arranged between and supported by vertical columns. 'I'hese are shown in Fig. 1 as the upright channels Ill. Together with the upright plates I2 they constitute the columns of the supporting framework of the furnace. These plates are ixediy secured tightly against the inner flanges of the column in the embodiment indicated in Figs. 1 and 9 of the drawings. In these iigures, as well as in Fig, 7, the plates are shown as extending considerably beyond the columns at either side. It is to these extensions that the wall sections are secured.

As indicated in Fig. 1 and more clearly in Fig. 9 ofthe drawings, the plates I2 are protected by constituting a backing for the insulating ilrebrick I4 which have a length corresponding to the width of the plates. 'I'hese refractories are held in position by reason of the fact that they are threaded upon restraining rods I6 which pass through brackets I8 welded to the plates. Near the top of each wall section these rods pass through clips 28 which are also welded to the plates. Similar but centrally positioned clips 26 are indicated in Fig. 11 of the drawings.

Between adiacent plates I2 and between adjacent columns, integral panel sections 22 are arranged. They preferably consist of sheet steel plates which have anges 23 around their marginal portions. Along the lower edge of each brackets 2 4 are welded to the .refractories, and the brackets to Figs. 7', 3.

panel furnace con-4 panels. They are spaced in a manner corresponding to the length or width of the refractory elements to be supported thereby, depending upon the arrangement of those elements. Above each bracket 2l there is a clip 25 which is in alignment with an upper clip 28. Both clips are preferably welded to the steel panel.

After the clips are welded to the steel panel the refractory elements 30 are placed in position. Thereafter a restraining rod 32 may be threaded through aligning openings in each set of clips, the hold a tier of in position. Insulation material 34 in the form of millboard blocks, or in the form of loose asbestos material, may be inserted between the steel panels and the refractory 30.

Fig. 1 shows a part of a furnace wall with the insulation 34 and one of the columns I0 broken away in the interest of clarity. Many of the insulating ilrebrick 30 are also omitted in order that the steelwork and the panels 22 may be more clearly shown. 'I'his view clearly indicates the construction of the columns and the means for holding the rebrick includes the plates I2 which maintain the column bricks I4 in position.

Fig. 1 also clearly indicates the panels 22 as having the outwardly extending flanges 23 around all sides. When the panels are in their operative positions the horizontal flanges of adjacent panels between the said pair ofcolumns are bolted together, copper covered asbestos gaskets being interposed.

Along the upright marginal portions of the panels apertures 40 are provided for the reception of screw threaded panel aligning studs 36. They are fixed to the plates I2 so as to extend outwardly therefrom. This detail of the furnace structure is clearly indicated in Fig. 26 of the drawings.

After one ofthe main wall units, such as the unit 38 of the Fis. 1 proximate alignment with the wall opening which is to receive it the unit is moved toward the wall so that the studs 36 are received within the apertures 40 along the upright margins of the unit. The unit is thus aligned with the opening so that it may be brought into operative position without destructive effects upon the gaskets which the refractories and the anchor rods are arranged along the margins of the unit. 'Ihls feature of the invention makes for a furnace encasement which is substantially airtight, thereby `promoting increased furnace eiliclency and permitting a close control of the furnace operation.

Fig. 1 shows the wall section unit 38 about to be placed in an opening within the wall between the first two columns I0 and upper and lower manner in which the wall unit may be removed, the interior of the furnace or the repair or replacement of some of the insulating refractories. Even when the units cover a furnace wall area of approximately 3 x 4 the weight of each unit is such that it can be readily lifted and handled by two workmen. Its weight is of the order of 350 lbs.

Fig. 2 illustrates a steam boiler construction in which the illustrative ployed at a relatively high elevation. The installationV here indicated corresponds generally to that of the central station referred to above. It includes a furnace 42 of considerable height. Superposed relative to the furnace is an encasefurnace encasement is eml thereon. This means disclosure, is elevated to apment 44 having the main panel wall umts indicated in the drawings by heavy black lines. Such panel units, or sections are shown arranged in upright rows between spaced columns. f

Within the encasement 44 there are arranged fluid heat exchange devices such as superheater sections, economizer sections, and a steam generating section. The latter includes the upright downtake headers 46 which are connected by a bank of steam generating tubes 48 to uptake headers 50. The latter are connected by circulators 52 to a steam 4and water drum 54. From the water space of the'latter downtake tubes 50 lead to the headers 46.

In many steam boiler installations similar to that indicated in Fig. 2 the furnaces themselves are located at a considerable distance above the foundation, and when the steam generating sections as well as the economizer and superhea-ter sections are superposed relative to the furnace, the entire installation reaches an elevation which in many cases is of the order of 100 above the foundation. to be of such height, it will bc readily appreciated that the invention involves large decreases in construction costs because of savings in the weight of materials. Eighty tons may be saved merely in the upper part of the installation (such as the encasement 44). Without isacriiicing operative advantages, this saving alone is no mean accomplishment, but this is not the only saving. There is also a large saving in the cost of the framework. and particularly in the columns such as those shown at 58 and 60 in Fig. 2. These columns support the boiler and its casing.

In the embodiments of the invention indicated i;n Figs. 7, 8, 9 and l0 of the drawings the tier sustaining brackets 62 are welded to the steel panels or plates 22 so that the general arrangement of these elements is the same as it is in the Fig. 1 embodiment. However, as distinguished from the Fig. 1 embodiment, each bracket is provided with two apertures. One of these is indicated at 64 as `receiving the lower end of the anchor rod 66. The other aperture is indicated at 68. When these brackets are in vertical alignment on successive panels in the same vertical row the lower end of the rod 66 will be received in the aperture 64, but in the aligned bracket 1,0 of the wall section immediately above, the anchor rods 12will be received in the bracket opening corresponding to 68. Thus lthe rods of vertically successive panels in the same row are oiset in the plane of the wall so that expansion of the rods may be taken up with a minimum of expansion joint spaces such as those indicated at 14 in Fig. 8. As shown, these spaces are between the brackets of an upper panel wall unit and the clips 16 of the next lower unit.

Fig. 8 shows the lowermost bricks'l of the upper unit to be upwardly recessed at their rearward portions and the upper bricks of the next lower unit to be downwardly recessed at their rearward portions so as to provide insulating refractory heat protecting wall portions in front of the metal parts in the expansion joint spaces. This heat protection may be supplemented by a frefelt curtain 82 which is shown in Fig. 8 as resting upon the ledge afforded by the bracket 10, and hanging down in front of that bracket and the clip 16.

The construction indicated above involves the boring of the bricks at off-center positions to provide apertures for receiving the anchor rods. This will be apparent from an inspection of Fig. 9 of Considering the Fig. 2 installation.

the drawings. Considering the brick 04 indicated in this figure it will be seen that the aperture for the anchor rod is toward the right of the center of the brick. When the brackets 62 on successive wall panel units in the same vertical row are in upright alignment and the bricks immediately below the brick 04 are in upright alignment therewith these lower bricks are reversed with reference to the brick 84 so that the, brick apertures will be in alignment with the bracket aperture 68.

Fig. 10 shows a 9" refractory lined wall in which the same brackets B2 are used. For this wall the brackets need only be arranged with a closer spacing across the panels. The anchor rod receiving apertures must, of course, be bored at different positions in the bricks of this wall, but these bricks may still be all bored uniformly. The bricks of the wall section below that indicated in Fig. l0 need merely be reversed to bring the anchor rods in offset positions at the joints between the units. It will thus be seen that each main panel wall section has fixed thereto a number of independently supported tiers of insulat- -ing rebrick. This permits the replacement of bricks in any ne tier without disturbing the bricks of any other tier in the same panel. Likewise the column bricks I4 may be removed or replaced when access is provided thereto by the detachment and removal of one of the wall units.

When the main panel units of the wall are large, intermediate restraining clips 86 may be employed along the central parts of the panels, as clearly indicated in Figs. '7 and 8. They are received within recessesin some of the intermediate refractories 08 and are preferably welded to the panels.

Figs. 7, 8 and 9 indicate the column gaskets 90 and the inter-panel gaskets 92 which may be of copper covered asbestos construction. In order that the column gaskets may be compressed uniformly batten strips 94 are used. They uniformly distribute the press-ure applied when the nuts 9B are tightened upon the panel aligning studs 36 to bind the wall parts in airtight relationship.

In the furnace wall shown in Figs. 13, 14 and 15, the panel wall units |00 and |02 have their tiers of refractory elements supported from brackets |04 which are preferably welded to the steel plates or panels |06. At the base of each panel wall unit there may be separate supports for the tiers, but in this instance there is shown a single bar |08 which extends across a plurality of tiers and acts as a bottom support. The anchor rods I I0 pass through apertures in the insulating firebrick. 'Ihey are secured at their tops to the brackets |04 and their lower ends act as direct supports for the bars |08, thus forming top hung supports for brick tiers in an integral panel construction in which the bricks expand upwardly whilethe anchor rods or hanger elements expand downwardly. In this way the two expansions tend to compensate each other, materially minimizing the problem of providing an airtight furnace encasement which will remain tight over wide ranges ofl furnace temperatures.

In the present instance rods ||0 are threaded through holes in the bars |08 and are provided with heads H2 which engage the lower surfaces of the bars. When'a plurality of bars |08 is provided, each tier of bricks may be separately removed by unbolting the supporting panel and removing the nut i |4 from the top of the hanger rod for that tier.

Each bar |08 may be provided with devices at movement of the tiers away from the panels while permitting independent up and down movements of the tiers resulting from expansion and contraction. Such devices may include slip brackets iid rigid with the bar and extending through the insulation iid. As shown, they are provided alongside the inner surface of the metal panel liliwith lugs l2@ which are freely movable through expansion clips l22 fixed to the casing plate or panel.

The expansion joint construction of the Fig. 13 wall is well illustrated in Fig. le. Here the tiers ci the panel liu are tree to move upwardly for a l5 limited distance and the refractarios of the panel it@ may move downwardly by reason of the slip bracket construction just described. At the exparisien joint i243, recessed bricks similar to those described with reference to the Fig. 8 construction are provided. Excessive heating of the brick supporting metal back of these recessed bricks atthe expansion joint is prevented by compressible heat insulating means such as the roll ci asbestos lil-ti.

The wall construction indicated in Figs. i6 and 17 includes supports t28 between which there are secured the casing panels i3d. The supports extend inwardly of the panels through the insulation layer 32 and the insulation layer i3d to positions intermediate the front and rear faces of the rebrick wall. This wall includes the refractories i3d strung upon upright anchor rods i3d which are engagedfby eye-bolts ilill holding the linsulation, the refractories, and the panels in a rigid compact structure. The rods H38 have reduced dowel-iike ends i412 extending through apertures in the supports t28. Further downward movement of the rods through these apertures is prevented by reason of the engagement i@ of shoulders upon the rods with the supports. In the present instance these shoulders are increased through the intermediacy of enlarged rod portions leid.

The supports t28 of the Fig. i6 wail are protected by means of specially formed refractories litt. They are recessed to receive the inner ends ci the supports so that the latter will be pro- `tected on all sides from direct exposure to the heat of the furnace. Each of these special bricks y tilt is also provided with a bore E58 which will permit the upper end of the rod of the next lower section to be moved upwardly so that the tiers of bricks may be released from interlocking engagement with the supports. The bores 50 in the upper parts of these specially formed bricks permit the enlarged rod portions 844 to move upi wardly to an extent sufficient to free the extensions itl? from the supports t28. The members |28 may be supported by buckstay columns similar to the columns ill shown in Fig. 1, and the plate l30 may be bolted to the columns and the members 62s. The corresponding members shown in Fig. 18'may be similarly supported.

of'Fig. 13 includes metal casing plates 552 and 'l 95d to which insulating rebricks 56 are secured .e means of rod and eye-bolt devices |58 similar to those which have already been described in connection with the wall structures. The separate panels of casing plates and i'lrebricks are upported at distributed positions fromopen steell" I6@ which is preferably made up of steel rilles similar to those used as subway grating. f ey not only provide walkways for workmen when the furnace arch is to be cleaned, repaired The furnace arch shown in the upper section or inspectedbut they also act as supports which will provide adequate ventilation for cooling the top of the furnace.

In the arch construction shown, hangers it? depend from the subway grille i6@ and are engaged with brackets lli secured to the panel sections of the arch.

Fig. 19 illustrates an arch construction in which sheet metal panels B66 have the insulating rebrick its secured thereto by rod and eye-bolt means il@ which extends through a layer of thermal insulation llt. The sheet metal panels are iianged as indicated' at il@ and the panels of adjoiningy arch sections are secured together at their iianges by means whichalso secures the hangers llt thereto. These hangers are nxed at their upper ends to steelwork il.

When the tiers or coursesoi the lrebrick Sltl are tightened against the insulation W2 so as to form a tight compact arch panel structure the firebrick are apt to be broken if excessive pressure is exerted, and this pressure does not have to be so great, because o the frangibility ci the illustrative insulating firebrick. Such breakage is prevented by means which are illustrated in Figs. 19, 20, 21 and 30. In the Fig. 2l struc-Y ture the eye-bolts il@ pass through sleeves ist which abut at one end against the plate it@ and at their other end against the eye portion of the eye-bolt or the anchor rod HB2. 'I'hese sleeves act as stops to limit the pressure which can be applied to the rebrick 88.

In the Fig. 30 modication the stops itil are threaded upon the eye bolts 68S before the latter are inserted through the openings in the panel it. The position to which the stop nuts are threaded along eye bolts determine the pressure to be exerted on the rebrick i9@ and the insulation E192 as well as the positioning and alignment of the iirebricks relative to the panel.

Fig. 18 shows a wall panel structure le@ in which the tiers of iirebrick are threaded upon long anchor rods 96 having reduced lower ends les passing through openings in the eye-beam 200. The tiers of refractories may be removed by moving the rods lg upwardly to disengage them from the beam 2W. The bottom of a tier may `be thereafter moved outwardly after removal of the top bricks of the laterally adjacent wall mi2. In this construction there is an adequate support for a high panel wall, all of the reiractories being in contact to act as compression supports throughout the vertical extent of the wall.

Figs. 24 and 25 indicate an arrangement of outwardly flanged panels with reference to column constructions which provide panel recesses having' surfaces normal to the furnace wail and tightly receiving the outer surfaces of the panels. Fig. 24, for instance, shows the panel plates 2M having right angle iianges 206 tightly received against the anges 208 and 2H) of the channel 2l2 which is secured to the column 2M. With this construction the joints between the columns and the main panel units are of greater depth. In considering this construction in the present manner, the column construction is taken as including the insulating rebricks M5, the length of which is the same as the width of the channel 2l2. The thermal insulation 2|8 is also included as a part of the column construction which is disposed between adjacent main wall panel units.

The mates indicated in Figures 13, 16, 18, 19, and

24 may be secured together in the manner ,indicated in Fig. 7 of the drawings.

the'plates 224 and this structure is unified by Sectional panel construction Figs. 3, 4, 5, 27 and 28 relate to a sectional panel construction in which the insulating firebricks are not carriedl by the casing plates. They are carried by supporting steelwork so that, after the separate casing plates are detached and the intermediate insulation 'is removed, each brick tier in a panel unit can be independently removed for the purpose of inspection or repairs. Referring particularly to Figs. 4 and 27 the insulating firebricks 228 are carried in separate tiers, the weight of the tiers being borne by panel structures which, include the channel sections 222. These sections are rigid with plates 224 extending between the steelwork columns 226 and fixed thereto at the ends of the beams. As shown, the webs of the channel sections are in contact with welding. Stud bolts 228 have their heads welded to the webs of the channel sections, 'as shown.

Extending inwardly of each composite beam including a channel section 222 and a plate 224 and preferably welded thereto, are brackets 229 each of which directly takes the load of a brick tier. These brackets have flat portions 288 which are formed with apertures 282 near their inner ends for receiving the anchor rods or brick restraining rods 284. On one side of each bracket there is a flange 286 increasingin height as the casing plate end of the bracket is approached. At the other side of the bracket there is a flange 238 which may also afford at its outer end an increased vertical metallic surface along which the bracket is welded to the plate 224. Both flanges also act together with the intermediate portion 288 to form a structure in the nature of 4a combination of angle stifl'eners for the brackets, besides increasing the area of the weld seam which secures the bracket to the plate 224. The weld seam, as indicated in Fig. 31 is of a Z-shaped outline, and it may be deposited by fusion welding.

Each of the vertical anchor rods 284 is welded near its lower end to a bar 240 which rests upon the flat portion 286 of a bracket 229. Below this bar the rod 284 extends through the bracket in order to prevent any substantial lateral movement of the tier of bricks supported by it while permitting the tier to be tilted as indicated below.

'Ihe flat panel casing plates 242 and 244 act as panels fitting between the lower and upper channel sections 222 and 246 respectively, and the intermediate anchor rod restraining eye-bolts 248. These eye-bolts pass through a removable horizontal bar 268 inside the casing. This bar may be backed up by fixed nuts 252 on the eye-bolts. It is preferably bolted at each end to short gusset plates 254 (see Fig. 12) secured to the steel columns 226.

Considering the tiers of bricks of the Fig. 4 structure and the contacting insulation layer 268 to be in the positions shown, and that the easing plates 242 and 244 are held`against the insulation, the plates may be then clamped in position by tightening the clamping channels 268, 262 and 264 against the wall. The channels 260 and 264 are placed in position upon the studs 228 and 266 so that they cover the outwardly opening channel sections 246 and 222, whereas the intermediate channel stiffener 262 is positioned upon the eye-bolts 248 and thereafter has its web tightened against the surfaces of the plates 242 and 244 with relatively large bearing surfaces in contact. The manner in which al1 of these channels will be tightened to secure the casing plates against the wall will be clear from an inspection of Fig. 4.

As also indicated in Fig. 4 the vertical restraining rods, or anchor rods 284 are threaded through the eye-bolts 248 along the center of the panel height, or at some position or positions intermediate the upper and lower ends of the tiers of bricks. The eye-bolts are received within recesses formed in the insulating flrebrick 268. Bowing of the anchor rods is thereby prevented.

Besides the channel sections above described g for tightening the casing plates against the wall there are vertical channels 210.*which act as batten strips to bind the remaining edges of the casing plates against gaskets 212 interposed relative to the vertical channels and the outwardly facing flanges 214 and 216 of the columns 226.

When it is desired to remove any tier of insulating firebrick from the illustrative sectional panel construction the three horizontal channels 260, 262 and 264 are detached and then the vertical channels 210 are removed. The casing plates 242 and 244 may then be taken from their wall forming positions. Thereafter the insulation layer 258 is taken out. 'I'his is easily done when this layer is in the form of millboard sections which are in the nature of long nat slabs or blocks. Thereafter the bar 258 is detached from the gussets 254 and removed. Then any tier of ilrebrick may be moved, as clearly indicated in Fig. 27. This is accomplished by tilting the upward end of the tier outwardly after the removal of the loose key brick 218, 286' and 282. (See Fig. 28.)

The key brick 288 may be easily pulled outwardly of the furnace because they are not threaded upon the anchor rods 284. When such bricks are removed their complementary bricks 218 may be removed by turning them around the adjacent brackets 228. Similarly all of the key brick may be removed including the sections 282 and 284. After a tier is moved to the dotted line position indicated in Fig. 27 of the drawings it may be lifted bodily away from its supporting bracket 229, the bar 241i and the anchor rod 284 maintaining the tier as a unit while it is being lifted outof its wall forming position.

A reversal of the above operations is involved in the replacing of any individual tier of rebrick. The lower end of the tier is first moved over .the top of the plate 224 and is allowed to rest on the bracket 228 with the lower end of its anchor rod extending through the opening 282. The upper end of the tier is then tilted inwardly of the furnace untilA theupper end of the rod 234 contacts with the stop 286 which is integrally formed as part of the bracket 228. This stop cooperates with the flange 288 and with an opposite downwardly extending flange 288 also preferably formed integrally on the bracket to form a pocket which keeps the rod 234 in its operative alignment and allows it to4 expand upwardly, room for such upward expansion being indicated in Fig. 27 of the drawings.

In order that each tier of rebrick in the sectional panel wall construction may be adequately supported as a separatesub-unit when it is being removed or replaced with reference to the remaining parts of the wall the bars 248 are arranged lengthwise of the bricks when a 41/2" refractory faced wall is provided after the manner indicated in Fig. 5 of the drawings. When a 9" refractory wall is provided with the ends of the bricks in contact with the insulation 268, as indicated in Fig. 6 of the drawings, wider foot ,Y .supports for said -wall panel areas,

bars ittmay be welded to the anchor rod 23|, or the bars 296 maybe employed at positions at right angles to those shown in Fig. 5.

As shown in Figs. 3 and i of 'the drawings, copper covered asbestos gaskets 292 and 294 may be employed between the plates 242 and 244 and the Idanges o the channel sections 25E. Similar gaskets 2% may be employed between the bars 2b@ and the other horizontal margins of the plates 2632 and 26M.

Elevating brackets 2Q@ and 30@ (as indicated in Figs. l1 and 12) may be provided'to facilitate theremcval of the panels and the plate sections when parts 'of the wall constructions are to be taken out or their operative positions.v

in connection with any ci the furnace constructions described herein y-ash erosion oi the brick may be minimized by kapplying a refractory coating to the furnace iaces ci the brick walls after the furnace is otherwise completed. Such coating may be applied-as a liquid which, when subjected to high furnace temperatures, forms a protective glazed layer over the inner surfaces of the furnace. Such a coating, or layer, is indicated by the numeral it in Fig. l of the drawings.

What is claimed is:

l. En a panel wall construction for furnaces, casing plates; tiers of firebrick; thermal insulating material between the'rebrlck and the plates; restraining rods extending through apertures in the rebricks and maintaining them in alignment and readily movable through the flrebrick for releasing the tiers irom their operative positions; bottom supports located at the lower parts of the panels and having apertures through which the lower ends of the rods extend; and means extending from the plates through the insulation to engage the rods for holding the respective tiers in rigid compact relationship to the plates and holding all ci the wall elements together in a rigid compact wall structure.

2. in a furnace wall, means including columns delineating panel areas in the wall, tiltable tiers ci" refractories including keyl bricks, and means including steel casing plates affording lateral support for said tiers in groups with each group covering a panel area, said means pressing the plates and tiers of each panel area against a layer of thermal interposed insulation material, the individual tiers of each panel area being separately removable after the removal of the plates and the insulation and their key bricks, said separate removal of the tiers beginning with the tilting of the tops of the tiers outwardly of the furnace.

3. ln a sectional panel wall furnace construction, a furnace supporting framework including columns connected by horizontal beams dening wall panels including a group of tiers of' insulating rebrickvfor each panel area, casing plates spaced outwardly of said tiers, thermal insulating material between the tiers and the plates, means secured to the beams and extending through the insulation to provide bottom tiers, stops preventing the tops of the tiers from tilting inwardly of the furnace, and means for binding the plates and the tiers against opposite sides of the insulation, said last named means including tiltable structures maintaining the bricks of each tier in vertical alignment.

li. n a steam boiler furnace, buckstay steelwork including columns, steel casing plates secured to the columns, tiers of insulating iirebrick spaced inwardly of the plates, a layer of thermal -tories to hold the each sub-unit to move extending through the layer to support the tiers, restraining rods threaded through said means and through apertures in the rebrick, and foot brackets rigid with on the rods when the tiers are separately removed or replaced.

5. In a panel furnace construction; identical main wall units, each unit comprising an outer casing plate, tiers ofv insulating refractories, and interposed thermal insuiation held tightly together and constituting the entire wall thickness of a furnace capable of withstanding temperatures in excess oi 2090 F. with a minimum oi heatloss; a plurality ci holding devices for the tiers of each main wall unit, the devices extending from the plate and into the tiers of refracplate and the refractarios against opposite sides ci the insulation; means so combining the reiractories oi the separate tiers that they constitute separate refractory sub-units which may be separately assembled and handled as self-sustaining component parts oi the main units; and inter-engaging supports malntaining the separate sub-units in operative positions as parts of the-main units while permitting independently of other sub-units of the same main unit.

6. In a furnace wall; independent wall sections each including exterior sheet metal casing plates and independently removable tiers of in-l sulating rebrick secured together to form a rigid compact structure with al layer oi insulating material between them; expansion joints at the insulation between the tiers and the plates, means v the rods to sustain the bricks 5 junctures of upper and lower tiers; and metallic means secured at positions adjacent the junctions of the sections for maintaining the tiers in position; the bottom bricks of an upper section being upwardly recessed at their rearward parts. and the top brick structure of an adjoining tower section being co-operatively recessed at their rearward parts to provide for expansion and contraction and for a space in which said means are located.

'7. In a furnace construction, metallic paneis, means co-acting with the panels to form an airtight furnace encasement, insulating rebrick refractories arranged in courses interiorly or the panels, retaining members extending through'the refractories, exterior supports for the refractories, thermal insulating material between the panels and the refractories, anchor means holding the refractories and the panels against the insulation, and stop devices on said anchor means preventing breakage of the refractories by excessive pressure against the insulation.

8. In a furnace, buckstays, composite wall units, means connecting the units to the buckstays, and means connecting adjacent units to form an airtight furnace encasement; each unit combining in aseparatestructure; an insulatingrebricklining, thermal insulation, and an exterior sheet metal panel with the insulation held in position between the lining and the panel by metallic bonding devices extending from the panel into the lining to directly tie those elements together while permitting relative movements of the rebrick and the associated panel, said rebrick lining formed by independently removable tiers. of insulating rebrick.

9.ln a furnace construction, an exterior wall' structure including sheet metal panels forming parts of a furnace encasement, supports to which said panels are secured in alignment, an inner wall including superposed insulating rebrick arranged in separate groups individually extending across the wall area covered by a panel, means for so supporting said rebrick groups that they may be removed when a panel is removed and without disturbing adjacent rebrick groups which have similar relations to adjacent panels, and bonding devices separate from the supporting means and arranged transversely of the inner and outer Walls and operating to directly tie said walls together, said bonding devices having their inner ends anchored within the inner wall and their outer ends secured to the panels, said bonding devices also acting to maintain normal wall relationships while permitting relative movements of the inner and outer walls due to temperature changes.

10. In a furnace construction, an exterior wall structure including sheet metal panels forming parts of a furnace encasement, supports to which said panels are secured in alignment, an inner wall including superposed insulating rebrick arranged in separate groups individually e'xtendl ing across the wall area covered by a panel, means for so supporting said rebrick groups that they may be removed when a panel is removed and without disturbing adJacent rebrick groups which have similar relations to adjacent panels, and bonding devices separate from the supporting means and including bolt-like elements arranged transversely of the inner and outer walls and operating to directly tie said walls together, said'bonding devices having their inner ends anchored within the inner wall and their outer ends secured to the panels, said bonding devices also maintaining the brick in vertical alignment and acting to maintain normal wall relationships while permitting relative movements of the inner and outer walls due to temperature changes.

JAMES E. BRINCKERHOF'F. ANTHONY M. KOHLER.. CARL S. REED. VINCENT WEAVER SMITH. 

